Toy motor



y 1952 s. B. BELIAEFF 2,598,211

TOY MOTOR Filed Sept. 1, 1950 INVENTOR. t-Palsy 3 urner/=- fmzjzk .6.;

Patented May 27, 1952 UNITED s- AYES FFEQ

TOY MOTOR Stephen B. Bcliaeff, Suffern, N. Y.

Application September 1, 1950, Serial N 0. 182,873

This invention pertains to toy motors; more particularly; it relates to a novel separately excited direct current'toy motor.

A commercially successful toy motor should combinesturdiness and compactness with utility. As the size of such a motor is decreased, it becomes increasingly diificult to retain the requisite sturdiness and utility because small parts are weaker than larger ones. Lightness must not be sacrificed for strength, but the latter is necessary if the motor is to be able to perform useful functions and not be too flimsy to be used as or in a'toy.

If the housing of 'atoy motor is cast metal, the

provide a device of the character described which is light and compact.

Another object of the present invention" is to provide a device of the character described, the

housing for Which is composed of few parts andis strong-and rugged.

Still another object of the present invention is to provide a device of the character described which iseasily and inexpensively manufactured.

Still a further object-of the present invention is to provide a device: of the character described whose assembly is so simple that it may be performed by unskilled workmen.

It is'another object of the present invention to-provide a device of the character described which may be rapidly manufactured on standard production machines by mass production methods.

It is a further object of thepresent invention to provide a device of the character described which comprises parts that canresist comparatively high temperatures.

Other objects of the invention will in part be obvious and in part will be pointed out hereposed at the middle of the curve.

shownone of the various possible embodiments of my invention,

Fig. l is a top view of a toy motor constructed in accordance with the present invention;

Fig. 2 is a sectional view taken'substantially along the line 2-2 of Fig. 1;

Fig. 3 isa terminal end view of the motor, part of the housing being broken away better to illustrate details of the commutator and brushes;

Fig. 4 is a perspective view of an end panel constituting part of the housing;

Fig. 5 is a'perspective view of an armature lamination;

Fig. dis a perspective view of aside element of the housing; and

Fig. 7- is a fragmentary side view of an end of the motor, being illustrative of the joint between the parts of the housing shown in Figs. 4 and 6.

Referring now in detail to the drawings, the

reference numeral Iii denotes a toy motor embodying the present invention. The motor housing H in part comprises a pair of sheet metal magnetic" elements I2, each of which includes a segmentally circular curved portion l4 whose concave inner surface constitutes a pole piece for the motor. The bottom of said curved portion is-integrally connected to a base portion 56 which is vertically disposed and is offset from the curved portion by an outwardly sloping panel H. The elements l2 preferably are fabricated, as by stamping, from a metal such as soft iron not having the property of permanent magnetism;

The housing-H further includes a pair of stiff end panels l8 each of which has a circular top portion 28 and a roughly trapezoidal lower'portion 2|. Said panels are fabricated, as by blanking, from' any durable non-magnetic sheet material, for example, sheet plastic, fibreboard or paperboard impregnated with a thermoplastic or thermosetting resin, the latter resin being preferred. The curvature of the top portion corresponds' to that of the inner surfaces of said pole pieces, and the lower portion is shaped to fit between the panels and base portions of the elements I 2. The circular top portion of each end panel is provided with an car 22 on each side, said ears being diametrically opposite one another and horizontally aligned. Similar ears 24- are provided on the base portion of said support. Through openings 2% are pierced'near both ends of the pole pieces l4, said openings being dis- In addition 3 through openings 2? are formed near both ends of the base portions 16 of the elements [2, these openings being vertically registered with the openings 23. The openings 26, 2! are located to receive the ears 22, 24 of the end panels l8.

To assemble the housing H, the two end panels (8 are fitted between opposite ends of the two elements 12 with the ears in the openings and the tops of the elements spaced apart. The pole pieces lie on opposite sides of the cylinder defined by the circular top portions of the end panels. The parts of the housing are held together firmly and rigidly by staking the elements [2 to the end panels it (see Fig. 7) This is accomplished by indenting the edges of the elements l2 in the regions of the openings whereby to constrict the openings on the ears.

The housing is completed by inserting a block 28 constituting a permanent magnet between the base portions l6. A suitable material for the magnet is Alnico V. This block is dimensioned and shaped to snugly fit between the base portions and may be held in place simply by its magnetism, the panels l'i acting as stops to prevent the magnet from riding up too far between the pole pieces.

One of the end panels I8 mounts a pair of spaced resilient metal strips 38 of an electrically conductive material, e. g. Phosphor bronze. Said strips project beneath the lower portion 21 of the end panel to form terminals 32 and extend upwardly slightly beyond the center of the circular top portion 20 and on opposite sides of this center to serve as brushes 33. The strips are disposed on the inner face of the end panel and taper upwardly, being bent to slant inwardly at a slight angle. The tips of the strips are rounded as viewed from the side to facilitate their sliding engagement as brushes. Eyelets 34 extend through holes 35 in the lower portion of the end panel and through matching holes in the strips, the ends of the eyelets being headed firmly to fix the strips on the panel. To prevent rotation of the strips, their terminal ends are oifset for reception in slots 36 in the lower edge of the panel. It should be noted that both end panels are similarly formed with holes 35 and slots 36 to expedite their joint manufacture, although the holes and slots are employed functionally in only one panel.

The circular top portion 26 of each end panel is formed with a central opening 35 which acts as a bearing rotatably receiving a journal end of a shaft $7 of an armature 33 for the motor. Said armature comprises several registered soft iron circular laminations 48 (Fig. stacked between two electrically non-conductive and non-magnetic laminations 42 which may be made of the same material as the end panels. All laminations are of the same shape and are similarly oriented. The laminations are force-fitted on a knurled central part of the shaft. Each lamination includes three equiangularly arranged slots 44 with constricted mouths and is formed with a central opening 46 in which the shaft is received. The diameter of the lamination is slightly less than the radius of the pole pieces so that the armature can revolve freely in the housing in proximity to the pole pieces. The laminations are conventionally wound with thin insulated copper wire 43 to form three coils, one around each registered set of radial arms defined by the slots 44.

Flange-ended tubular sleeves 50 are forcefitted on the knurled portion of the shaft on opposite sides of the laminations, the flanges 52 being remote from the laminations. One flange is located at the end of the knurled portion, this flange being designed to serve as a thrust bearing and ride on the inner face of the end panel on which no brushes are mounted.

The other flange functions as an abutment for a commutator 54. Said commutator includes an electrically non-conductive disk 56 which may be blanked from the same sheet stock as that employed for the end panels. Said disk is formed with a central opening in which the knurled portion of the shaft is force-fitted, the disk being in contact with said other flange. A narrow washer 58 is force-fitted on the shaft being pushed up against the disk 56.

Said disk supports three flat sheet metal commutator sectors 60 of electrically conductive material, these sectors each constituting slightly less than one-third of a full circle so that when the sectors are arranged on the disk, the radial edges thereof are slightly spaced apart to insulate the same from one another. The inner edges of the sectors are disposed near the periphery of the narrow washer 58, this washer being thicker than the sectors so that the washer protrudes beyond the same, and will serve to absorb thrust in the event that the armature is inadvertently shifted in a direction toward the brushes. The outer edges of the sectors are in registry with the periphery of thedisk 56. Each sector is held in place by a pair of tines 62 which are frictionally received in suitable through openings in the disk. Each sector, moreover, includes a rearwardly extending prong 64 which is seated in a peripheral indentation in the disk and protrudes beyond the disk. These prongs are used as electrical terminals to which the ends of the armature coils are attached.

The electrical wiring for the armature is conventional, that is to say, the three coils are connected in series and each point of connection is electrically connected to a different one of the prongs. The brushes ride on the sectors and as the armature revolves effect commutation in a conventional manner.

It will be observed that the brushes urge the armature toward the remote end panel thereby making certain that normally axial thrust is absorbed by the first-named flange 52. However, as noted above, if through accidental mishandling, or for any other reason, the armature is axially shifted toward the brush-carrying end panel, the washer 58 will serve as a thrust bearing and ride against the inner face of said panel.

When D. C. potential is applied to the terminals 32, the motor II] will operate in the same manner as a conventional separately excited direct current motor.

The housing is very light since it is constructed from only four thin main elements; nevertheless, it is sturdy as the staked joints serve to prevent any relative motion of the end panels and magnetic elements and can be quickly assembled due to the simple nature of said joints. Moreover, the panels and magnetic elements are strong enough to withstand much abuse and are resistant to overheating.

It thus will be seen that there has been provided a device which achieves all the objects of the invention and is well adapted to meet the conditions of practical use.

As various possible embodiments might be made in the above invention, and as various changes might be made in the embodiment above set forth, itis to be understoodthat all matter herein described, or shown in the accompanying curved portions, being centered with respect. to the armature shaft and ofa radiusrof curvature:

slightly greater than that of the'armature, each said element having a downwardly extending base portion, said base portions being spaced apart to form an open bottom, said pole pieces being located on diametrically opposite sides of said armature, non-magnetic stiff end supports having edges shaped to fit said magnetic elements, said supports having aligned openings in which said shaft is journalled, said elements having through slots near opposite ends thereof, said supports having ears received and captively held in said slots, and a member received in said bottom and bridging said base portions, said member being of high permeability, said member and elements constituting the means to produce a field, said member, elements and supports constituting the housing.

2. A housing for a direct current toy motor including a commutator, means to produce a field and an armature having a shaft: said housing comprising two sheet metal magnetic elements, each said element having a curved portion the inner surface of which is segmentally circular and constitutes a pole piece of the motor, said curved portions being centered with respect to the armature shaft and of a radius of curvature slightly greater than that of the armature, each said element having a downwardly extending base portion, said base portions being spaced apart to form an open bottom, said pole pieces being located on diametrically opposite sides of said armature, non-magnetic stiff end panels having edges shaped to fit said magnetic elements, said panels having aligned openings in which said shaft is journalled, means to permanently and rigidly attach said panels directly to said elements, and a member received in said bottom and bridging said base portions, said member being of high permeability, said member and elements constituting the means to produce a field, said member, elements and panels constituting the housing.

3. A housing for a direct current toy motor including a commutator, means to produce a field and an armature having a shaft: said housing comprising two sheet metal magnetic elements of impermanently magnetic material, each said element having a curved portion the inner surface of which is segmentally circular and constitutes a pole piece of the motor, said curved portions being centered with respect to the armature shaft and of a radius of curvature slightly greater than that of the armature, each said element having a downwardly extending vertical base portion, said base portions being spaced apart to form an open bottom, said pole pieces being located on diametrically opposite sides of said armature, non-magnetic stiff end supports having edges shaped to fit said magnetic elements, said supports having aligned openings in which said shaftis journalled,.means. toper manently and rigidly attach saidsupports directly to said elements, a' permanentv magnet" bridging said base portions. and'inserted therebetween whereby the field between said polel pieces is produced, said. magnet, elements, and supports constituting said housing, and stop.

means to limit insertion of said magnet.

4. A housing for adirect current toy motor including a commutator and an armature having" a shaft: said housingcomprising a pair of'nonmagnetic and electrically non-conductive flat parallel sheet end panels having aligned openings inwhich the shaft is journalled, a'pair of soft iron sheet elements connected to and supported by and on opposite sides of said end panels, the bases of said elements being spaced apart to form an open bottom, and a permanent magnet in the space between the bases of said elements and contacting the same, said magnet being retained in position by its magnetism.

5. A housing as set forth in claim 4 wherein the elements include portions projecting over the magnet to limit upward movement of the same.

6. A housing for a direct current toy motor including a commutator and an armature having a shaft: said housing including a pair of parallel non-magnetic and electrically non-conductive fibrous sheet end panels having aligned apertures in which the shaft is journalled, a pair of soft iron sheet elements on opposite sides of said panels, said elements having openings and said panels having ears extending through said openings and tightly received therein, the bases of said elements being spaced apart to provide an open bottom, and a permanent magnet disposed in said bottom contacting the bases of the elements and held in place by its own magnetism.

'7. A housing as set forth in claim 6 wherein each end panel has a circular top portion and a rectangular base portion connected to the top portion by an upwardly tapering portion, the inner surface of the elements matching the contiguous contour of said top, rectangular and tapering portions.

8. A direct current toy motor including a shaft: a stack of armature laminations tightly fitted on said shaft, coils wound about said armature laminations, a disk of electrically non-conductive material tightly fitted on the shaft, a plurality of conductive commutator sectors carried by the disk, electric connections between said coils and sectors, a sleeve tightly fitted on the shaft between one side of the laminations and the disk, said sleeve having a flange on which the disk is seated, a second sleeve tightly fitted on the shaft on the other side of the laminations, said second sleeve having a flange remote from the lamina tions, a pair of parallel non-magnetic and electrically non-conductive fibrous end panels having aligned openings in which the shaft is journalled, a pair of soft iron sheet elements disposed on opposite sides of the end panels, said elements having openings, said panels having peripheral ears received in and tightly held in said openings, the

base portions of said elements being spaced apart, a permanent magnet between and contacting said base portions and held in place by its own magnetism, and a pair of brushes carried by one of said panels and resiliently pressing against the commutator sectors, the second-named flange riding against the other end panel.

9. A motor as set forth in claim 8 wherein the brushes comprise a pair of resilient electrically conductive strips having tips engaging the sectors, and means to support said strips from an end panel, said supporting means constituting a pair of eyelets, each eyelet extending through a hole in the strip and a hole in the panel, the ends of said eyelets being headed, a pair of indentations in said panel, a portion of each strip being disposed in an indentation to prevent rotation thereof.

10. In a direct current toy motor having an armature shaft, a housing including an end panel of non-magnetic and electrically non-conductive sheet material, a pair of brushes carried by said panel, said brushes constituting resilient strips of electrically conductive material, and means to support said strips from said panel, said supporting means constituting a pair of eyelets, each eye- 8 let extending through a hole in the strip and a hole in the panel, the ends of said eyelets being headed, and a pair of indentations in said panel, a portion of each strip being disposed in an indentation to prevent rotation thereof.

STEPHEN B. BELIAEFF.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS Number Name Date 2,453,101 Schulz Nov. 2, 1948 2,456,967 Livers Dec. 21, 1948 2,465,446 Gorfin et al Mar. 29, 1949 

